Basic structures made from recycled scrap tires

ABSTRACT

A dock bumper made from rubber material derived from scrap tires with a trapezoidal cross-section, a trapezoidal side profile, a base, and an optional longitudinal lumen. The longitudinal lumen also has a trapezoidal cross-section and may be open at one or both ends. The dock bumper is further provided with mounting holes for mounting on a surface. The mounting hole includes an opening for a fastener and an indentation in which a plug maybe securely installed to cover the fastener. A guardrail cover adapted for installation over a conventional crash barrier guardrail. A variety of rubber encased pillars, including crash barrier pillars on which guardrails are mounting, coast walls, and railroad ties. The rubber encased pillars are concrete-filled steel beams encased in rubber material derived from recycled scrap tires. The rubber encased railroad ties include raised sections for mounting and supporting railroad tracks.

BACKGROUND

1. Field of the Invention

This invention relates to basic structures for civil engineering applications made from recycled scrap tires.

2. Related Art

The U.S. Environmental Protection Agency (“EPA”) estimated that 290 million scrap tires were generated in 2003, in addition to the 275 million scrap tires in existing stockpiles at that time. Scrap tires are recycled to produce crumb rubber, via processes in which the steel and fiber reinforcement components of the tires are removed. The single largest U.S. market for crumb rubber is asphalt rubber, in the construction of highways and other roadways. The EPA also lists other civil engineering applications for crumb rubber, predominantly as filler material.

In the past, whole scrap tires have been used as dock bumpers on piers, marinas, and bridges, and as crash barriers. However, such uses of whole scrap tires are not ideal as they first require substantially uniform tire sizes. Even if this first requirement is achieved, the different degrees of fatigue or wear and tear of the tires preclude uniform impact absorption.

SUMMARY

This invention is directed to a variety of basic structures for civil engineering applications made from rubber material derived from the recycling of scrap tires, including, for example, dock bumpers, guardrails and guardrail covers, rubber encased pillars, coast walls, and rubber encased railroad ties. The rubber components of these structures are made from recycled scrap tires. During the recycling process, the scrap tires are shredded and the steel and fiber reinforcement components of the tires are removed to yield “crumb” rubber. Rubber material is recovered from the crumb rubber and renewed to produce the starting rubber material for the manufacture of these products. The appropriate die, for example, a steel-rule die, can then be used to make the products from the starting rubber material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a top plan view of a dock bumper according to one embodiment of the present invention.

FIG. 1B is a side elevation view of the dock bumper in FIG. 1A.

FIG. 1C is an end elevation view of the dock bumper in FIG. 1A.

FIG. 2A is a top plan view of a dock bumper according to another embodiment of the present invention.

FIG. 2B is a side elevation view of the dock bumper in FIG. 2A.

FIG. 2C is an end elevation view of the dock bumper in FIG. 2A.

FIG. 3 is a top plan view of a dock bumper according to yet another embodiment of the present invention.

FIG. 4A is an isometric view of an exemplary fastener and a complementary plug.

FIG. 4B is an isometric view of the exemplary fastener and the complementary plug shown in FIG. 4A from the opposite perspective.

FIG. 4C is a perspective view of the complementary plug shown in FIG. 4A.

FIG. 4D is a top plan view of the complementary plug shown in FIG. 4A.

FIG. 4E is a side elevation view of the complementary plug shown in FIG. 4A.

FIG. 5 is a perspective view rendering showing multiple dock bumpers of FIGS. 1A-1C installed onto a surface.

FIG. 6 is a top plan view of a guardrail cover according to one embodiment of the present invention.

FIG. 7A is a side elevation view of the guardrail cover in FIG. 6.

FIG. 7B is an end elevation view of the guardrail cover in FIG. 6.

FIG. 8A is a side elevation view of a rubber encased pillar according to another embodiment of the present invention.

FIG. 8B is a top plan view of the rubber encased pillar in FIG. 8A.

FIG. 9 is a side elevation view of the rubber encased pillar in FIG. 8A from a perspective perpendicular to that in FIG. 8A.

FIG. 10A is a side perspective view of the guardrail cover in FIG. 6 installed on a conventional crash barrier guardrail.

FIG. 10B is a three quarter perspective view of the guardrail cover in FIG. 6.

FIG. 10C is front perspective view of the guardrail cover in FIG. 6.

FIG. 11 is a perspective view rendering showing multiple railroad ties according to one embodiment of the present invention.

FIG. 12A is a top plan view of the railroad tie in FIG. 11.

FIG. 12B is a side elevation view of the railroad tie in FIG. 11.

FIG. 12C is a front perspective view of the railroad tie in FIG. 11.

FIG. 12C is an end elevation view of the railroad tie in FIG. 11.

FIG. 12D is a top plan view of the steel beam core in FIG. 11.

DETAILED DESCRIPTION 1. Dock Bumper

With reference to the drawings, FIGS. 1A, 1B, and 1C are illustrative of one embodiment, a dock bumper for a wharf, pier, dock, bridge, or other building or structures where vehicles may dock, or where contact between vehicle and structure may be expected. Structures are not limited and may include structures built on or in water, for example, wharfs, pies, docks, and bridges, as well as structures built on land, for example, a loading dock in a warehouse.

FIGS. 1A, 1B, and 1C illustrate a dock bumper 10 with a trapezoidal cross-section and a trapezoidal side profile, i.e., shape when viewed from its side. In other embodiments the cross section of the dock bumper may be, for example, semi-circular, curved, rectangular, or square, and the side profile of the dock bumper may be, for example, rectangular or curved.

The dock bumper 10 illustrated in FIGS. 1A, 1B, and 1C is provided with a base 12. In the illustrated embodiment the base 12 is integrated with the dock bumper 10 and formed as a single piece. In other embodiments the base 12 may be provided as a separate layer. The thickness of the base 12 may be varied to adjust the degree of impact absorption of the dock bumper 10.

The dock bumper 10 illustrated in FIGS. 1A, 1B, and 1C is further provided with a longitudinal lumen 14. In the illustrated embodiment the lumen 14 opens on one end of the dock bumper 10. In other embodiments, the lumen 14 may be either open or closed at either end of the dock bumper 10. While not shown as such in FIGS. 1A, 1B, and 1C, the lumen 14 may extend into the base 12 of the dock bumper 10 in other embodiments. The dimensions of the lumen 14 and the thickness of the surrounding walls may be varied to adjust the impact absorption of the dock bumper 10.

In other embodiments the dock bumper is not provided with a lumen. FIGS. 2A, 2B, and 2C illustrate a dock bumper 20 that is solid, without a lumen. The dock bumper 20 has an integrated base 22 and the two are formed as a single piece. In other embodiments the base 22 may be provided as a separate layer. The thickness of the base 22 may be varied to adjust the impact absorption of the dock bumper 20. While the dock bumper 20 has a trapezoidal cross-section and a trapezoidal shape when viewed from its side, the invention is not so limited, and other embodiments may have different shaped cross-sections and/or side profiles, as discussed above with reference to the dock bumper 10.

As shown in FIG. 3, a dock bumper, for example dock bumper 20 (or 10, not shown in FIG. 3), may be additionally provided with one or more mounting holes 24 adapted for mounting dock bumper 20 onto the surface of the structure on which dock bumpers are installed. In the embodiment illustrated in FIG. 3, a mounting hole 24 comprises a circular opening 26 and a square indentation 28. The circular opening 26 is adapted for a bolt or other fastener to pass through the dock bumper 20 for mounting the dock bumper 20 onto a surface, while the square indentation 28 is adapted for the installation of a plug to cover the bolt or other fastener.

FIG. 4 illustrates an exemplary fastener, here a bolt 30, which may be used to mount a dock bumper onto a surface. FIG. 4 also illustrates a plug 32 that is adapted to fit into the square indentation 28 (illustrated in FIG. 3) and cover the bolt 30. As shown in FIG. 4, the plug 32 may be additionally provided with a recess 34 for the head of the bolt 30. In the illustrated embodiment, the recess 34 has the same hexagonal shape as the head of the bolt 30, enabling the plug 32 to be fit more securely onto the head of the bolt 30. In other embodiments the recess may have alternate shapes, for example circular, as long as the recess is of sufficient size for the head of the fastener. In some embodiments the plug may not be provided with a recess at all.

The dimensions of dock bumper 10 or dock bump 20 may be varied to conform to the surface of the structure on which dock bumpers are installed, and/or to adjust the degree of impact absorption. FIG. 5 illustrates a plurality of dock bumpers 10 mounted onto a surface by a plurality of bolts 30. As shown in FIG. 5, the dock bumpers 10 are preferably mounted flush against one another to provide protection of the surface on which they are mounted. While FIG. 5 illustrates a surface uniformly covered by dock bumpers 10, two or more different types of dock bumpers, for examples dock bumpers 10 and 20, may be used on the same surface. For example, where different areas on one surface have different impact absorption requirements, two or more different types of dock bumpers may be installed.

Dock bumpers 10 and 20 are made from crumb rubber from recycled scrap tires. During the first phase of the recycling process, the scrap tires are shredded and the steel and fiber reinforcement components of the tires are separated and removed, leaving granular or “crumb” rubber, typically with a particle size of approximately 40 mesh. The crumb rubber may then undergo additional processing to reduce the particle size.

In the second phase of the recycling process, rubber material is recovered from the crumb rubber and renewed to produce the starting rubber material for the manufacture of dock bumpers (and other products). The appropriate die, for example, a steel-rule die, can then be used to make the dock bumpers from the starting rubber material.

Dock bumpers made from rubber recycled from scrap tires offer the advantages of being water-proof, impact-resistant, erosion-proof, corrosion-proof and insect-proof. Compared to the use of whole scrap tires as boat bumpers at wharfs, piers, and marinas, the dock bumpers of the present invention further offer the advantages of improved aesthetics and more uniform impact protection.

While nominally called “dock bumpers,” the dock bumpers of this invention may also be mounted on supporting pillars of bridges and other structures to protect against accidental impact from vehicles, in addition to structures against which vehicles may be docked.

2. Crash Barriers and Guard Rails

According to another aspect of this invention, crash barriers with guardrails are made from crumb rubber obtained from the recycling of scrap tires. Crash barriers with guardrails may be installed along the sides of roadways to protect motorists, cyclists, pedestrians and buildings, or as center dividers to separate traffic in opposite directions.

FIGS. 6, 7A, and 7B illustrate a guardrail cover 40. As shown in FIG. 7B, the guardrail cover 40 has a C-shaped cross-section that defines an interior channel 42. This allows the guardrail cover 40 to be installed over a conventional crash barrier guardrail 44, as shown in FIGS. 10A, 10B, and 10C. Other embodiments of guardrail covers may have different cross-sections that allow them to be installed over conventional crash barrier guardrails. Alternatively, the guardrail cover may be bonded onto a convention crash barrier guardrail, in which case it does not need to be provided with an interior channel.

The dimensions of the guardrail cover 40 are not limited and may be varied as necessary to ensure an appropriate fit over the guardrail 44 on which the guardrail cover 40 is installed. The thickness of the guardrail cover 40 may also be varied to adjust the degree of impact absorption.

The guardrail covers 40 are made from crumb rubber derived from recycled scrap tires. In the first phase of the recycling process, the scrap tires are shredded and the steel and fiber reinforcement components of the tires are separated and removed, leaving granular or “crumb” rubber, typically with a particle size of approximately 40 mesh. The crumb rubber may then undergo additional processing to reduce the particle size.

In the second phase of the recycling process, rubber material is recovered from the crumb rubber and renewed to produce the starting rubber material for the manufacture of guardrail covers. The appropriate die, for example, a steel-rule die, can then be used to make the guardrail covers from the starting rubber material.

Additionally, guardrail cover 40 may be made from rubber material formulated with colored dyes to improve its visibility at night or during inclement weather. Reflective tape or paint may also be applied onto guardrail cover 40 to improve its visibility.

Compared to conventional guardrails, the addition of guardrail cover 40 improves impact protection, especially during low speed collisions between vehicles and guardrails.

3. Rubber Encased Pillar

FIGS. 8A, 8B, and 9 illustrate a rubber encased pillar 46. In this embodiment, the rubber encased pillar 46 has a concrete-filled steel beam core, and the steel beam core is encased in rubber material derived from crumb rubber obtained from the recycling of scrap tires. In other embodiments another metal or material may be used for the core beam, and the core beam may also be hollow or filled with a material other than concrete. Referring again to FIGS. 8A, 8B, and 9, the rubber encased pillar 46 may be provided with one or more holes 48 so that guardrails 44 may be mounted on the rubber encased pillar 46 by the use of bolts or other fasteners, as shown in FIGS. 10A, 10B, and 10C.

The cross-sectional shape and dimensions of the rubber encased pillars 46 are not limited, and may be varied as necessary to provide an appropriate mounting height for guardrail 44, and to meet other safety considerations relating to potential collisions between vehicles and guardrail 44 and/or pillar 46.

According to another aspect of this invention, a plurality of rubber encased pillars 46 can be bound or linked together with steel cables to form a coast wall, to be installed along a coast or river bank to mitigate erosion or scouring of the coastline or river bank.

The rubber encased pillars 46 are made from crumb rubber derived from recycled scrap tires. During the first phase of the recycling process, the scrap tires are shredded and the steel and fiber reinforcement components of the tires are separated and removed, leaving granular or “crumb” rubber, typically with a particle size of approximately 40 mesh. The crumb rubber may then undergo additional processing to reduce the particle size.

In the second phase of the recycling process, rubber material is recovered from the crumb rubber and renewed to produce the starting rubber material for manufacturing rubber encased pillars (and other products). The steel-beam core is preferably encased in the starting rubber material without the use of special binders or glues.

4. Rubber Encased Railroad Ties

According to yet another aspect of this invention, a rubber encased railroad tie is made from crumb rubber obtained from recycled scrap tires. Similar to the rubber encased pillar 46 discussed above with reference to FIGS. 8A, 8B, 9, 10A, 10B, and 10C, a steel beam core is encased in rubber material derived from crumb rubber obtained from the recycling of scrap tires to produce a rubber encased railroad tie 60, as shown in FIG. 11. In other embodiments another metal or material may be used for the core beam, and the core beam may also be hollow or filled with a material other than concrete.

FIGS. 12A, 12B, 12C, and 12D illustrate a rubber encased railroad tie 60 according to one aspect of the present invention. In the illustrated embodiment, the steel beam core 62 has a constant rectangular cross-section that maintains the same width and height from end to end, such that the rubber encased railroad tie 60 is provided with two raised rubber sections 64, one at each end of the rubber encased railroad tie 60, for mounting and supporting railroad tracks (not shown). The two raised rubber sections 64 offer improved shock absorption and dampening compared to a convention railroad tie. The raised rubber sections 64 may be further provided with mounting holes 66 for the mounting of railroad tracks (not shown). The rubber encased railroad tie 60 also offers the additional advantages of being water-proof, erosion-proof, and corrosion-proof and is immune to insects or rodents, and is stronger and more durable than its conventional counterpart.

In another embodiment, the steel beam core itself may have a raised section at each end, and be encased in a layer of rubber material of substantially uniform thickness to form a rubber encased railroad tie.

Highly durable, these rubber encased railroad ties have steel-beam core filled with concrete that is then encased in 140 to 150 pounds of rubber material, preferably without the use of a special binder or glue. These railroad ties are over 200% stronger than wooded ties, and used longer than wood or concrete railroad ties. In some embodiments, the size of the railroad ties is 10 inches by 10 inches by 96 inches. 

1. A dock bumper made from rubber material derived from scrap tires.
 2. The dock bumper of claim 1, wherein the dock bumper has a trapezoidal cross-section and a trapezoidal side profile.
 3. The dock bumper of claim 2, wherein the dock bumper additionally comprises a base.
 4. The dock bumper of claim 3, wherein the base is integrated with the dock bumper.
 5. (canceled)
 6. The dock bumper of claim 4, additionally comprising a longitudinal lumen.
 7. The dock bumper of claim 6, wherein the longitudinal lumen has a trapezoidal cross-section.
 8. The dock bumper of claim 8, additionally comprising a mounting hole for mounting the dock bumper onto a surface.
 9. (canceled)
 10. (canceled)
 11. The dock bumper of claim 8, additionally comprising a mounting hole for mounting the dock bumper onto a surface.
 12. The dock bumper of claim 11, the mounting hole additionally comprising an opening adapted for a fastener for mounting the dock bumper onto the surface, and an indentation adapted for installing a plug to cover the fastener.
 13. The dock bumper of claim 12, wherein the opening is circular and the indentation is square.
 14. The dock bumper of claim 12, wherein the plug additionally comprises a recess adapted to fit securely over a head of the fastener.
 15. (canceled)
 16. (canceled)
 17. (canceled)
 18. (canceled)
 19. (canceled)
 20. (canceled)
 21. A rubber encased pillar made from rubber material derived from scrap tires.
 22. The rubber encased pillar of claim 21, comprising a steel beam core encases in rubber material.
 23. The rubber encased pillar of claim 22, wherein the steel beam core is filled with concrete.
 24. The rubber encased pillar of claim 23, wherein the rubber encased pillar has a square cross-section.
 25. The rubber encased pillar of claim 24, additionally comprising a mounting hole.
 26. (canceled)
 27. A rubber encased railroad tie made from rubber material derived from scrap tires.
 28. The rubber encased railroad tie of claim 27, comprising a steel beam core encased in rubber material.
 29. (canceled)
 30. The rubber encased railroad tie of claim 28, wherein the steel beam core has a constant rectangular cross-section, the railroad tie additional comprising two raised rubber sections.
 31. The rubber encased railroad tie of claim 28, wherein the steel beam core has a raised section at each end.
 32. The rubber encased railroad tie of claim 30, additionally comprising mounting holes for mounting a railroad track. 